Outer sole component with co-molded flex modifier component for footwear sole structure

ABSTRACT

A sole structure for an article of footwear includes an outer sole component with a co-molded flex modifier component. The outer sole component is formed of a first mold material, such as a rubber mold material. The flex modifier component includes a fiber material and a second mold material. The second mold material may be mold compatible with the first mold material. The sole structure may be formed by co-molding an outer sole component blank or pre-form (e.g., rubber mold material), and a flex modifier component, e.g., in a hot press molding process using a molding system having a mold cavity configured to form the outer sole component. The flex modifier component may be formed (e.g., cut or stamped) from a sheet of flex modifier material, such as a thermoplastic extruded hot melt film sandwiched between fusion bonded non-woven fiber fabric material impregnated with a styrene-coated polymer.

FIELD OF THE INVENTION

The present embodiments generally relate to articles of footwear. Moreparticularly, the present embodiments relate to an outer sole componentfor a footwear sole structure.

BACKGROUND

Articles of footwear generally include an upper and a sole structure. Anupper generally forms a footwear body that extends over a portion of afoot to retain the article of footwear on the foot. An upper may extendover an instep and toe area of the foot, along medial and lateral sidesof the foot, and/or around a heel area of the foot. An upper may beformed from one or more material elements, such as textiles, polymersheet layers, foam layers, leather, synthetic leather, and othermaterials. These materials may be attached together, such as bystitching or adhesive bonding. An upper may be configured to form aninterior of the footwear that comfortably and securely receives a foot.An upper may include an opening that facilitates entry and removal ofthe foot from the interior of the upper, and further may include aclosure or fastening system, such as lacing, cinches, or straps, toadjust a fit of the article of footwear.

A sole structure generally is attached to the upper and disposed betweenthe foot and a ground surface. For example, a sole structure may beattached to a lower portion of the upper. A sole structure may includeone or more components, including one or more outer sole component,midsole component, insole, insert, bladder or fluid-filled chamber, suchas an airbag, or other sole component. A sole structure also may includeother components, elements, or features, such as ground surface tractionelements.

An upper and sole structure may operate to provide a comfortable articleof footwear structure configured to benefit a wearer engaged in any of avariety of activities. A sole structure may operate to attenuate impactand ground reaction forces and/or to provide traction on a groundsurface. An upper and sole structure may cooperate to control variousfoot motions, such as pronation.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments may be better understood with reference to the followingdrawings and detailed description. Elements, components, and features ofthe embodiments in the figures are not necessarily drawn to scale,emphasis instead being placed upon illustrating principles of theembodiments disclosed. In the figures, like reference numerals designatelike or corresponding parts or features throughout the different views,with the initial digit(s) of each reference numeral indicating a figurein which the reference numeral first appears.

FIG. 1 is a schematic diagram illustrating a side perspective view of anembodiment of an article of footwear having a sole structure includingan outer sole component with a co-molded flex modifier component;

FIG. 2 is a schematic diagram illustrating an exploded side perspectiveview of the article of footwear of FIG. 1;

FIG. 3 is a schematic diagram illustrating an exploded perspective viewof an embodiment of a flex modifier material and a removing device forremoving a flex modifier component from the flex modifier material in aremoving process;

FIG. 4 is a schematic diagram illustrating a plan view of an embodimentof a flex modifier component formed from the flex modifier material ofFIG. 3;

FIG. 5 is a schematic diagram illustrating a cross-sectional view of theflex modifier component of FIG. 4, taken along section line 5-5 of FIG.4;

FIG. 6 is a schematic diagram illustrating a perspective view of anembodiment of a molding system for molding an outer sole component witha co-molded flex modifier component, with the molding system in an open,pre-molding state;

FIG. 7 is a schematic diagram illustrating a perspective view of themolding system of FIG. 6 in a closed, molding state;

FIG. 8 is a schematic diagram illustrating a perspective view of themolding system of FIG. 6 in an open, post molding state;

FIG. 9 is a schematic diagram illustrating a top plan view of anembodiment of a molded sole structure including an outer sole componentwith a co-molded flex modifier component, prior to a finishing process;

FIG. 10 is a schematic diagram illustrating a top plan view of a moldedsole structure including an outer sole component with a co-molded flexmodifier component;

FIG. 11 is a schematic diagram illustrating a cross-sectional view ofthe sole structure of FIG. 10, taken along section line 11-11 of FIG.10;

FIG. 12 is a schematic diagram illustrating a side perspective view ofan embodiment of a sole structure including an outer sole component witha co-molded flex modifier component, with the sole structure in a flexedconfiguration;

FIG. 13 is a flow diagram illustrating an embodiment of processes formaking a flex modifier component; and

FIG. 14 is a flow diagram illustrating an embodiment of processes formaking a sole structure for an article of footwear including an outersole component with a co-molded flex modifier component.

DETAILED DESCRIPTION

The following description and accompanying figures disclose embodimentsof sole structures for articles of footwear incorporating an outer solecomponent with a co-molded flex modifier component. Features andconcepts related to the footwear, and more particularly to the solestructure including an outer sole component with a co-molded flexmodifier component, are disclosed with reference to athletic footwearhaving a configuration that is suitable for a soccer cleat. Theembodiments are not limited to athletic footwear configured for a soccercleat, however, and may be applied to a wide range of footwear styles.For example, features and concepts of the embodiments may be applied toother athletic footwear, including basketball shoes, cross-trainingshoes, walking shoes, tennis shoes, running shoes, hiking boots, andother athletic footwear. Features and concepts of the embodiments alsomay be applied to non-athletic footwear styles, including dress shoes,loafers, sandals, work boots, and other non-athletic footwear. Oneskilled in the art will appreciate that features and concepts of thedisclosed embodiments may apply to a wide variety of footwear styles, inaddition to the specific styles discussed in the following descriptionand depicted in the accompanying figures.

Sole structures according to embodiments described herein may providedesired improvements in one or more performance characteristics ofathletic footwear or other articles of footwear. For example, a solestructure including an outer sole component with a co-molded flexmodifier component may provide a desired rigidity or flex characteristicand attenuate impact and ground reaction forces and other forces. A solestructure including an outer sole component with a co-molded flexmodifier component may be combined with other components, such as amidsole component formed of a foam material, to provide a comfortablefit, e.g., by conforming to various contours of the foot, with a desiredrigidity or flex characteristic and response to impact and groundreaction forces, and to provide a range of customization in a solestructure and article of footwear. Embodiments described herein mayprovide improvements in small sized footwear, such as junior or women'sfootwear, including football or soccer cleats. Embodiments herein mayprovide customization, e.g., player- or position-specific rigidityand/or flex characteristics, in an outer sole component and article offootwear, that may be selected (i.e., customized) during manufacture.Embodiments described herein may facilitate efficient and/or costeffective manufacture of such sole structures and articles of footwear.

In one aspect, a sole structure for an article of footwear includes anouter sole component formed of a first mold material, the outer solecomponent having an exposed or bottom surface configured to engage aground surface and an interior or top surface opposite the exposedsurface, and a flex modifier component formed of a fiber material and asecond mold material, the flex modifier component being co-molded withthe outer sole component at the interior surface of the outer solecomponent.

In some embodiments, the flex modifier component may have a multi-layerconstruction that includes at least a first layer formed of fibermaterial. In some embodiments, the fiber material may be a non-wovenfiber fabric or mat material. In some embodiments, the fiber materialmay be impregnated with a polymer material, such as a styrene-coatedpolymer material, and in some embodiments, the polymer material may bemold compatible with the first mold material of the outer solecomponent. In some embodiments, the fiber material may be afusion-bonded non-woven fabric material. In some embodiments, themulti-layer construction may include an extruded hot melt filmsandwiched between fiber fabric material layers. For example, in someembodiments the flex modifier component may be an extruded thermoplastichot melt film sandwiched between fusion bonded non-woven fabric,impregnated with a styrene-coated polymer. In some embodiments, the flexmodifier component may be co-molded with the outer sole component sothat mold material of the flex modifier component naturally fuses orblends with a rubber compound of the outer sole component and creates achemical and mechanical bond.

In some embodiments, a configuration, location, and/or orientation ofthe flex modifier component may be selected to cooperate with aconfiguration of the outer sole component to selectively modify a flexcharacteristic of the outer sole component substantially only at aselected location of the outer sole component corresponding to thelocation of the flex modifier component, e.g., to control natural flexand motion of an article of footwear. In some embodiments, the flexmodifier component may be an elongated shank. In some embodiments, theelongated shank may extend through a midfoot region generally from aheel region to a forefoot region of the outer sole component. In someembodiments, the elongated shank may be generally rectangular. In someembodiments, the elongated shank may have an extended portion orprojection, e.g., a portion at a longitudinal end of the elongated shankmay be configured to extend or project within a region located between aplurality of traction elements arranged in a pattern on the exposedsurface of the outer sole component, such as in the heel region of theouter sole component. Such selective modification may be implemented inmanufacturing to provide variability and customization in performancecharacteristics, e.g., for player- or position-specific performancecharacteristics.

In another aspect, an article of footwear includes an upper and a solestructure associated with the upper, the sole structure including anouter sole component formed of a first mold material, the outer solecomponent having an exposed surface configured to engage a groundsurface and an interior surface opposite the exposed surface, and a flexmodifier component formed of a fiber material and a second moldmaterial, the flex modifier component being co-molded with the outersole component at the interior surface of the outer sole component.

In some embodiments, the sole structure of the article of footwear mayinclude a midsole component disposed between the upper and the outersole component with the co-molded flex modifier component.

In another aspect, a method of making a sole structure for an article offootwear includes disposing an outer sole component blank of a firstmold material in a mold cavity of a molding system that is configured tocorrespond with an outer sole component, disposing a flex modifiercomponent that includes a fiber material and a second mold material onan exposed upper surface of the outer sole component blank, andco-molding the outer sole component blank and the flex modifiercomponent in the molding system to form the outer sole component, withthe co-molded flex modifier component located at an interior surface ofthe outer sole component.

In another aspect, a method of making a flex modifier component includespreparing a flex modifier material and forming a flex modifier componentfrom the flex modifier material. In some embodiments, the method mayinclude preparing a multi-layer sheet of flex modifier material, such asan extruded thermoplastic hot melt film sandwiched between fusion bondednon-woven fiber fabric material impregnated with a styrene-coatedpolymer. The flex modifier component may be formed from the flexmodifier material by a removing process, such as a cutting or stampingprocess, using a removing device, such as a stamp, a punch, or a cookiecutter device.

Each of the above aspects, embodiments, and features may improve atleast one performance characteristic of a sole structure of an articleof footwear. In particular, these aspects, embodiments, and features,alone and/or in combination, variously may provide a desired rigidity orflex characteristic in a sole structure and article of footwear. Theseaspects, embodiments, and features further may facilitate a smoothresponse characteristic in a sole structure of an article of footwear,where localized bending of the sole structure occurs smoothly andwithout buckling. Further, these aspects, embodiments, and featuresvariously may be combined with one another and/or with other features toimprove overall performance of a sole structure and article of footwear.

Other systems, methods, aspects, features, and advantages of embodimentswill be, or will become, apparent to one of ordinary skill in the artupon examination of the figures and this detailed description. It isintended that all such additional systems, methods, aspects, features,and advantages be included within this description, be within the scopeof the embodiments, and be protected by the following claims.

Article of Footwear Features

FIGS. 1 and 2 illustrate an embodiment of an article of footwear 100.FIG. 1 is a lateral side perspective view of article of footwear 100,and FIG. 2 is an exploded lateral side perspective view of article offootwear 100. As shown in FIGS. 1 and 2, article of footwear 100generally includes an upper 102 and a sole structure 103. As shown inFIGS. 1 and 2, in some embodiments sole structure 103 may include anoptional midsole component 104, an outer sole component 106, and a flexmodifier component 208.

Referring to FIG. 1, article of footwear 100 generally includes a heelregion 110, a mid-foot region 112, and a forefoot region 114 including atoe region 116. Article of footwear 100 generally includes a medial side118 and a lateral side 120. In this disclosure and the claims, referenceto heel region 110, mid-foot region 112, forefoot region 114, toe region116, medial side 118, and lateral side 120 does not refer to exactstructure(s) or boundaries, but rather generally designates regions orareas of article of footwear 100. In some aspects, these regions orareas may overlap. It will be appreciated that reference to heel region110, mid-foot region 112, forefoot region 114, toe region 116, medialside 118, and lateral side 120 also may apply to various elements orcomponents of article of footwear 100, such as upper 102, sole structure103, optional midsole component 104, outer sole component 106, and flexmodifier component 208. Further, the term “lateral” may be used todescribe a medial-lateral direction or orientation of article offootwear 100 or a component or portion of article of footwear 100.Similarly, the terms “rear,” “front,” “forward,” “proximal,” or “distal”may be used to describe a direction, orientation, or relative location,e.g., along a lateral direction from heel region 110 to toe region 116of article of footwear 100 or a component or portion of article offootwear 100. Similarly, the term “vertical” may be used to describe adirection perpendicular to a ground surface when article of footwear 100is disposed with sole structure 103 laying substantially flat on theground surface. Those skilled in the art will be able to interpret thesereferences and terms throughout the disclosure and claims based on thecontext in which these references and terms are used in the disclosureand claims.

A construction and configuration of upper 102 may vary in differentembodiments. Upper 102 may have any construction and configurationsuitable for a desired article of footwear. As shown in FIGS. 1 and 2,in some embodiments upper 102 may extend over toe region 116, forefootregion 114, an instep at midfoot region 112, along medial side 118,along lateral side 120, and around heel region 110. Upper 102 mayinclude one or more material elements, such as textiles, foam materials,leather materials, and other known or later developed materials, thatmay be associated with one another, e.g., stitched or adhesively bondedtogether. One or more material elements may be manipulated or configuredto form an interior of upper 102 for securely and comfortably receivinga foot. Those skilled in the art readily will be able to select aconstruction and configuration of upper 102 suitable for a desiredapplication based on the present disclosure.

A construction and configuration of sole structure 103 may vary indifferent embodiments. Sole structure 103 may include plural components.As shown in FIGS. 1 and 2, in some embodiments sole structure 103 mayinclude midsole component 104, outer sole component 106, and co-moldedflex modifier component 208. In some embodiments, midsole component 104may be optional. For example, in some embodiments sole structure 103 mayinclude only outer sole component 106 and co-molded flex modifiercomponent 208. Sole structure 103 may include an optional insole orinner sole (not shown), which may be a thin cushioning member typicallylocated within the interior of upper 102 and adjacent to the foot toenhance the comfort of article of footwear 100. Those skilled in the artwill appreciate alternative constructions and configurations for solestructure 103 suitable for a desired application consistent withdescriptions of embodiments herein.

Sole structure 103 may be secured to upper 102 in various configurationsin different embodiments. As shown in FIGS. 1 and 2, in some embodimentssole structure 103 may be secured to a lower surface of upper 102, suchas by stitching or adhesive bonding. For example, in some embodimentsouter sole component 106 may be secured to optional midsole component104 and/or upper 102, such as by stitching or adhesive bonding. Thoseskilled in the art will appreciate alternative methods suitable forsecuring sole structure 103 to upper 102 consistent with descriptions ofembodiments herein.

Sole structure 103 generally operates to attenuate impact and otherground reaction forces and absorb energy. Sole structure 103 mayattenuate impact and other ground reaction forces and absorb energy asit contacts a ground surface or other surface, such as a ball or otherequipment, during active use of article of footwear 100. In someembodiments, one or more of optional midsole component 104, outer solecomponent 106, and co-molded flex modifier component 208 of solestructure 103 may cooperate to attenuate impact and other groundreaction forces and absorb energy. In some embodiments, one or more ofoptional midsole component 104, outer sole component 106, and co-moldedflex modifier component 208 of sole structure 103 may cooperate toprovide one or more other performance characteristics of article offootwear 100, such as control of pronation. Those skilled in the artwill appreciate alternative configurations of these elements forachieving these and other performance characteristics of sole structure103 in view of discussion of these elements in this disclosure.

Midsole Component Features

A construction and configuration of optional midsole component 104 mayvary in different embodiments. As shown in FIGS. 1 and 2, in someembodiments midsole component 104 may be located below upper 102 andadjacent a foot when the foot is disposed in an interior of upper 102.In some embodiments, midsole component 104 may be secured to a lowerportion of upper 102, e.g., by stitching or adhesive bonding. In someembodiments, midsole component 104 may be attached to a lower portion ofupper 102 and an upper surface of outer sole component 106, e.g., bystitching or adhesive bonding. In some embodiments, midsole component104 may include one or more elements. As shown in FIG. 2, in someembodiments midsole component 104 may be a single, one-piece midsolecomponent or element. In some embodiments, midsole component 104 may besubstantially planar. In some embodiments, midsole component 104 mayhave a shape (in plan view) that generally conforms to a foot orfootprint. In some embodiments, one or more surface contours of midsolecomponent 104 may be configured to generally conform to one or morecontour of the foot, to provide a comfortable fit. Those skilled in theart will be able to select a configuration of midsole component 104,including at least shape and geometry, suitable for a desiredapplication based on the present disclosure.

A construction of midsole component 104 may vary in differentembodiments. Midsole component 104 generally may be made of any materialsuitable for use as a midsole. In some embodiments, midsole component104 may provide the foot with cushioning during walking, running, orother activities. In some embodiments, midsole component 104 may be madeof a foam material. It will be appreciated that foam material maybeneficially compress resiliently under an applied load, e.g., toprovide a desired absorption and/or dissipation of impact or otherground reaction forces. In some embodiments, midsole component 104 maybe formed of a polymer foam material, such as polyurethane orethylvinylacetate. In some embodiments, the polymer foam material mayhave an open cell foam construction; in some embodiments, the polymerfoam material may have a closed cell foam construction. In someembodiments, midsole component 104 may be formed of a material that ismold compatible with, or otherwise suitable for attachment with, outersole component 106 and/or flex modifier component 208, such as byadhesive or thermal bonding.

Midsole component 104 may be made by various processes in differentembodiments. In some embodiments, midsole component 104 may be made byany manufacturing method or process suitable for making a foam materialcomponent. For example, in some embodiments midsole component 104 may bemade by injection molding a polymer foam material. Those skilled in theart will appreciate alternative and additional materials and methods ofmaking optional midsole component 104 suitable for a desired applicationbased on the present disclosure.

Outer Sole Component Features

A construction and configuration of outer sole component 106 may vary indifferent embodiments. As shown in FIGS. 1 and 2, outer sole component106 may be disposed below upper 102 and optional midsole component 104.As shown in FIG. 2, in some embodiments outer sole component 106 mayhave a generally planar structure. As shown in FIG. 2, in someembodiments outer sole component 106 may have a general shape of afootprint. In some embodiments, e.g., in embodiments where optionalmidsole component 104 is not present, outer sole component 106 may havetop surface contours that generally conform to features of a foot, e.g.,to provide a comfortable fit. In some embodiments, a surface contour ofat least a portion of a perimeter of outer sole component 106 may curlvertically upward, e.g., to conform to a curved surface contour of anouter perimeter of a lower portion of upper 102. In some embodiments, atleast a portion of outer sole component 106, e.g., an outer perimeterportion, may be attached directly to a lower portion of upper 102, e.g.,by stitching or adhesive bonding. In some embodiments, e.g., inembodiments where optional midsole component 104 is not present, asubstantial entirety of a top surface of outer sole component 106 may beattached directly to a lower surface of upper 102, e.g., by stitching oradhesive bonding. As shown in FIGS. 1 and 2, outer sole component 106generally may be disposed below upper 102 and configured to engage aground surface and impart traction to article of footwear 100.

A construction of outer sole component 106 may vary in differentembodiments. Outer sole component 106 may be formed of various materialsin different embodiments. In some embodiments, outer sole component 106may be formed of a durable, wear-resistant material that is configuredto engage a ground surface and impart traction. In some embodiments,outer sole component 106 may be formed of a mold material, such as arubber mold material or other mold material. In some embodiments, outersole component 106 may be formed of more than one mold material. In someembodiments, outer sole component 106 may be formed of a mold materialand another material, such as a filler material or insert. Those skilledin the art will appreciate various combinations of mold materials andoptional other materials suitable for making outer sole component 106based on the present disclosure.

Outer sole component 106 may include at least one traction elementconfigured to engage a ground surface and impart traction. In someembodiments, at least one traction element may be integrally molded as asingle piece with outer sole component 106. In some embodiments, one ormore traction elements may be removably attached to an exposed surfaceof outer sole component 106, e.g., using a base member that may bethreaded or otherwise suitably mated with a receiving structure of outersole component 106. In some embodiments, outer sole component 106 mayinclude a plurality of traction elements arranged on an exposed surfaceof outer sole component 106. In some embodiments, outer sole component106 may include a plurality of different types of traction elementsarranged in a pattern on an exposed surface of outer sole component 106.For example, as shown in FIGS. 1 and 2, in some embodiments outer solecomponent 106 may include at least one traction element located in toeregion 116, such as conical-shaped cleat 121 and conical-shaped cleat122. As shown in FIGS. 1 and 2, in some embodiments outer sole component106 may include at least one traction element located in forefoot region114, such as conical-shaped cleat 123 and conical-shaped cleat 124. Asshown in FIGS. 1 and 2, in some embodiments outer sole component 106 mayinclude at least one traction element located in heel region 110, suchas blade cleat 125 and blade cleat 126. In some embodiments, one or moretraction elements may be located in midfoot region 112. Those skilled inthe art will appreciate other types of traction elements and locationsor patterns of traction elements suitable for any desired applicationbased on the present disclosure.

In some embodiments, outer sole component 106 may be configured with atleast one flex structure or flex zone. For example, as shown in FIG. 2,in some embodiments outer sole component 106 may include flex structureor flex zone 212 located on an exposed bottom surface of outer solecomponent 106. In some embodiments, flex structure or flex zone 212generally may be located in forefoot region 114, e.g., at a locationcorresponding to the metatarsals adjacent the balls of the feet. It willbe appreciated that flex structure or flex zone 212 may facilitatedesired localized bending or flexing of outer sole component 106 andsole structure 103 at flex structure or flex zone 212. Those skilled inthe art will be able to select a location of flex structure or flex zone212 suitable for a desired application based on the present disclosure.

A configuration of flex structure or flex zone 212 may vary in differentembodiments. Flex structure or flex zone 212 may have any regular ornon-regular shape or geometric configuration in plan view. In someembodiments, flex structure or flex zone 212 may have a generallyrectangular shape in plan view. As shown in FIG. 2, in some embodimentsflex structure or flex zone 212 may have a generally rectangular shape,e.g., generally defined between dashed line 213 and dashed line 214 inforefoot region 114. In some embodiments, one or more longitudinal orlateral side edges of flex structure or flex zone 212 may be curved. Forexample, as shown in FIG. 2, in some embodiments at least one oflongitudinal sides of flex structure or flex zone 212, indicated atdashed line 213 and dashed line 214, may be arched inward. In someembodiments, a lateral width of flex structure or flex zone 212 mayextend an entire width of outer sole component 106. In some embodiments,a lateral width of flex structure or flex zone 212 may extend only aportion of the width of outer sole component 106. Those skilled in theart will be able to select a configuration of flex structure or flexzone 212, including at least size and shape in plan view, suitable forproviding desired bending or flex characteristics base on the presentdisclosure.

In some embodiments, flex structure or flex zone 212 may be formed bycontrolling a width profile of outer sole component 106. In someembodiments, a width profile of outer sole component 106 at flexstructure or flex zone 212 may be smooth or gradual. For example, insome embodiments outer sole component 106 may have a first width at onelongitudinal end of flex structure or flex zone 212 located moreproximate heel region 110, e.g., at dashed line 213, a second width at acentral location of flex structure or flex zone 212, and a third widthat an opposite longitudinal end of flex structure or flex zone 212 moreproximate the toe region 116, e.g., at dashed line 214. In someembodiments, outer sole component 106 may have a substantially parallelwidth profile at flex structure or flex zone 212, e.g., in which thefirst width, the second width, and the third width are substantiallyequal. In some embodiments, outer sole component 106 may have a smoothtapered width profile at flex structure or flex zone 212, e.g., in whichthe second width is less than at least one of the first width and thethird width and at least one lateral side edge curves inward.

In some embodiments, a width profile of outer sole component 106 at flexstructure or flex zone 212 may not be smooth or gradual. In someembodiments, a width profile at flex structure or flex zone 212 may bediscontinuous or stepped, e.g., at dashed line 213 and/or at dashed line214, at least on one of medial side 118 and lateral side 120. In someembodiments, flex structure or flex zone 212 may be formed by one ormore notches or cut-out portions formed on at least one of opposinglateral side edges of article of footwear 100. For example, as shown inFIG. 2, in some embodiments outer sole component 106 may include flexstructure or flex zone 212 formed by notched or cut-out portion 215located on medial side 118 and notched or cut-out portion 216 located onlateral side 120 of article of footwear 100. In some embodiments,notched or cut-out portion 215 and notched or cut-out portion 216 mayhave substantially similar but opposing shapes, e.g., substantiallymirror image shapes. In some embodiments, notched or cut-out portion 215and notched or cut-out portion 216 may have different configurations.For example, in some embodiments notched or cut-out portion 215 andnotched or cut-out portion 216 may have different sizes, differentshapes, asymmetrical relative shapes, asymmetrical alignments, or otherdifferent configurations. Those skilled in the art will be able toselect a configuration, including size and shape of any notched orcut-out portion(s) suitable for a desired application based on thepresent disclosure.

In some embodiments, a flex structure or flex zone 212 may be formed bycontrolling a thickness profile of outer sole component 106. As shown inFIG. 2, in some embodiments outer sole component 106 may have a reducedthickness profile at flex structure or flex zone 212, e.g., a reducedthickness relative to a thickness at at least one adjacent portion ofouter sole component 106. For example, as shown in FIG. 2, in someembodiments outer sole component 106 may have a thickness profile atflex structure or flex zone 212 that tapers from a first thickness 217at one longitudinal end of flex structure or flex zone 212 located atforefoot region 114 more proximate heel region 110 (e.g., at dashed line213), down to a second thickness 218 at a central area of flex structureor flex zone 212, and then back up to a third thickness 219 at anopposite longitudinal end of flex structure or flex zone 212 at forefootregion 114 more proximate toe region 116 (e.g., at dashed line 214).With this configuration, in some embodiments the second thickness 218may be less than at least one of the first thickness 217 and the thirdthickness 219. In some embodiments, thickness 219 may be less thanthickness 217. In some embodiments, thickness 218 may be located at amidpoint of flex structure or flex zone 212, e.g., at a midpoint betweendashed line 213 and dashed line 214. In some embodiments, thickness 218may be a minimum thickness at flex structure or flex zone 212. Forexample, in some embodiments second thickness 218 may be approximately50% of at least the greater of thickness 217 and/or thickness 219. Insome embodiments, thickness 218 may be a minimum thickness of outer solecomponent 106. As shown in FIG. 2, in some embodiments a thicknessprofile of outer sole component 106 at flex structure or flex zone 212may have a smooth or continuous surface contour or configuration. Insome embodiments, however, a thickness profile of outer sole component106 at flex structure or flex zone 212 may not have a smooth orcontinuous surface contour or configuration. In some embodiments, athickness profile of outer sole component 106 at flex structure or flexzone 212 may have a discontinuous surface configuration, such as astepped thickness profile. For example, in some embodiments flexstructure or flex zone 212 may include a sipe, a channel, a slottedstructure, or another stepped or discontinuous profile structure. Thoseskilled in the art will be able to select a thickness profile of outersole component 106 at flex structure 212 suitable for achieving adesired bending or flex characteristic at flex zone 212 based on thepresent disclosure.

With a configuration of sole component 106 including at least one ofthese profile features or another flex structure or flex zone profilefeature, it will be appreciated that flex structure or flex zone 212 mayfacilitate a desired localized bending or flex characteristic of outersole component 106 and sole structure 103. For example, as shown in FIG.2, in some embodiments flex structure or flex zone 212 may be locatedbetween at least one first traction element (e.g., traction element 122generally located proximate toe region 116) and at least one secondtraction element (e.g., traction element 123 generally located inforefoot region 114 more proximate midfoot region 112) to providedesired localized bending or flex characteristics in outer solecomponent 106 and sole structure 103 at forefoot region 114. In someembodiments, flex structure or flex zone 212 may be located belowmetatarsals proximate the balls of the foot (see also FIG. 12, discussedbelow). Those skilled in the art will appreciate alternative andadditional locations, width profiles, thickness profiles, and otherfeatures for flex structures or flex zones suitable for obtainingdesired localized bending or flex characteristics of outer solecomponent 106 and sole structure 103.

Flex Modifier Component Features

A construction and configuration of flex modifier component 208 may varyin different embodiments. Flex modifier component 208 generally may bean element formed of a fiber material configured to provide a desiredrigidity characteristic to a selected portion of outer sole component106 and sole structure 103. In some embodiments, flex modifier component208 may be a shank.

A configuration of flex modifier component 208, including size, shape,and/or geometry, may vary in different embodiments. In some embodiments,flex modifier component 208 may be generally flat or planar. Flexmodifier component 208 generally may be any geometric or non-geometricshape in plan view. In some embodiments, flex modifier component 208generally may include a main body 220 and optionally may include one ormore extended portions or projections. An extended portion or projectionmay have any geometric or non-geometric shape in plan view. For example,as shown in FIG. 2, in some embodiments flex modifier component 208 mayinclude an elongated main body 220 and an extended portion or projection222 that extends or projects from a rear portion of main body 220 in adirection of heel region 110. Those skilled in the art will be able toselect a configuration of flex modifier component 208 suitable forproviding a desired rigidity characteristic for outer sole component 106and sole structure 103.

A location and orientation of flex modifier component 208 may vary indifferent embodiments. In some embodiments, flex modifier component 208generally may extend in a longitudinal direction of outer sole component106, i.e., in a direction generally from heel region 110 toward toeregion 116. As shown in FIG. 2, in some embodiments flex modifiercomponent 208 may extend through midfoot region 112 of outer solecomponent 106, generally from heel region 110 to forefoot region 114.For example, in some embodiments flex modifier component 208 may belocated in an instep or arch portion of outer sole component 106, e.g.,at midfoot region 112. In some embodiments, flex modifier component 208may be oriented relative to a longitudinal or lateral direction of outersole component 106, e.g., at an angle relative to a longitudinal orlateral direction of outer sole component 106. For example, as shown inFIG. 2, in some embodiments flex modifier component 208 may be generallyaligned with a longitudinal direction of outer sole component 106. Thoseskilled in the art will be able to select a particular location andorientation of flex modifier component 208 suitable for desired rigidityor flex characteristics and performance characteristics in view of thepresent disclosure.

Portions of flex modifier component 208 variously may extend or projectinto selected locations, areas, or regions of outer sole component 106in different embodiments. For example, as shown in FIG. 2, in someembodiments extended portion or projection 222 may extend or projectinto heel region 110. In some embodiments, at least a portion of a widthof extended portion or projection 222 may be less than a width of mainbody 220, e.g., so that extended portion or projection 222 may extendinto heel region 110 between two or more of a plurality of tractionelements (e.g., cleats) arranged in a pattern in heel region 110 (seealso discussion of FIGS. 9 to 12 below). With this configuration,extended portion or projection 222 may be provided at leastsubstantially outside of an area in which individual traction elementsof the plurality of traction elements are located in heel region 110. Itwill be appreciated that, in this manner, flex modifier component 208may be selectively located so as to modify rigidity and/or flexcharacteristics of outer sole component 106 substantially only atselected locations of outer sole component 106, e.g., at a location(s)that is outside of the area that includes a plurality of tractionelements. It further will be appreciated that, with this configuration,flex modifier component 208 may provide desired rigidity or flexcharacteristics to a selected portion of outer sole component 106 andarticle of footwear 100 while enabling different desired rigidity and/orflex characteristics and other performance characteristics at otherportions of outer sole component 106 and sole structure 103 for articleof footwear 100.

A construction of flex modifier component 208 may vary in differentembodiments. Flex modifier component 208 generally may be formed of afiber material and a mold material or binder material. In someembodiments, e.g., where outer sole component 106 is formed of a firstmold material, flex modifier component 208 may include a second moldmaterial that is the same as, or mold compatible with, the first moldmaterial. It will be appreciated that, with this construction, in someembodiments flex modifier component 208 may be co-molded with outer solecomponent 106 by at least one of a chemical bond and a mechanical bond.In some embodiments, flex modifier component 208 may be co-molded withouter sole component 106 so that flex modifier component 208 generallymay be located at an upper or interior surface of outer sole component106. In some embodiments, flex modifier component 208 may be co-moldedwith outer sole component 106 so that an upper surface of flex modifiercomponent 208 may be substantially continuous or flush with an uppersurface of outer sole component 106. It will be appreciated that thisconfiguration may facilitate efficient manufacturing using a co-moldingprocess (see also discussion below). With this configuration, in someembodiments co-molded flex modifier component 208 may be substantiallyembedded or incorporated into an upper surface of a molded body of outersole component 106.

Generally, flex modifier component 208 may include a fiber material,mold material, construction, and configuration that provide desiredrigidity and/or flex characteristics to a selected portion of an outersole component and sole structure for an article of footwear. In someembodiments, flex modifier component 208 may be made from a planar flexmodifier material, such as a sheet of flex modifier material.

FIGS. 3 to 5 illustrate features of embodiments of a planar flexmodifier material and methods for making a flex modifier component fromthe planar flex modifier material. FIG. 3 is an exploded perspectiveview of an embodiment of a multi-layer sheet of flex modifier material301 and a removing device 305 for forming a flex modifier componenthaving a desired configuration (including at least shape 306) from thesheet of flex modifier material 301. FIG. 4 is a plan view of anembodiment of a flex modifier component 400 formed from the flexmodifier material of FIG. 3 in a removing process. And FIG. 5 is across-sectional view of flex modifier component 400 of FIG. 4 takenalong lines 5-5 of FIG. 4.

A construction of flex modifier material 301 may vary in differentembodiments. As shown in FIG. 3, in some embodiments flex modifiermaterial 301 may have a multi-layer construction including at least onelayer of fiber material. As used in this description and the claims,fiber material means a material made or formed of one or more fiber(s),where a fiber is an element having high aspect ratio or ratio of lengthto diameter (or thickness). For example, in some embodiments, shortfibers, also known as discontinuous fibers, may have an aspect ratio orratio of length to diameter in a range of 20 to 60. In some embodiments,long fibers, also known as a continuous fibers, may have an aspect ratioor ratio of length to diameter in the range of 200 to 500. A fibermaterial may be formed of one or more natural fiber(s), one or moreman-made fiber(s), or a combination of one or more natural and/orman-made fibers. In some embodiments, a fiber material may be formed ofcellulose fibers. In some embodiments, a fiber material may be formed ofsemi-synthetic fibers, such as rayon, which generally are naturallylong-chain polymer structures. In some embodiments, a fiber material maybe formed of synthetic fibers, such as polyamide (e.g., nylon) orpolyester (e.g., Dacron), which generally are synthesized fromlow-molecular weight compounds by a polymerization reaction. In someembodiments, a fiber material may be a fiber fabric material. In someembodiments, a fiber material may be a non-woven fiber fabric material,such as a non-woven fiber mat. For example, in some embodiments a fibermaterial may be a fusion bonded non-woven fiber fabric material.

In some embodiments, flex modifier material 301 may include at least onelayer of fiber material and at least one layer of binder or bondingmaterial. In some embodiments, flex modifier material 301 may include alayer of binder or bonding material and a layer of fiber material. Insome embodiments, flex modifier material 301 may include a layer ofbinder or bonding material sandwiched between two layers of fibermaterial. For example, as shown in FIG. 3, in some embodiments flexmodifier material 301 may include a first layer 302, which may bedisposed between a second layer 303 and a third layer 304. In someembodiments, first layer 302 may be a layer of binder or bondingmaterial. In some embodiments, second layer 303 and third layer 304 eachmay be layers of fiber material. In some embodiments, first layer 302may be an extruded hot melt film material sandwiched between secondlayer 303 and third layer 304, which both may be layers of fusion bondednon-woven fiber fabric material. In some embodiments, third layer 304may be optional, as indicated by dashed perimeter lines in FIGS. 3 and5. In some embodiments, third layer 304 may be made of another material,e.g., a non-fiber material.

In some embodiments, flex modifier material 301 may include a layer(e.g., first layer 302 of FIG. 3) formed of a plastic material that maymechanically and/or chemically bond with a mold material of an outersole component (e.g., mold compatible with a rubber mold material ofouter sole component 106 of FIG. 2). Examples of such plastic materialmay include, but are not limited to, Texon, Nylon 6, Nylon 12, and otherpolymers or polyamide (or “PA”) materials that generally exhibit highmechanical strength, high rigidity, and good stability under heat. Thoseskilled in the art will be able to select a plastic material suitablefor providing desired mechanical strength, rigidity, and stabilitycharacteristics under heat suitable for a desired flex modifiermaterial.

A flex modifier component may be formed from a flex modifier material byvarious processes in different embodiments. In some embodiments, a flexmodifier component may be removed from a flex modifier material, such asflex modifier material 301 in FIG. 3, by a removing process. In someembodiments, a removing process may include a cutting or stampingprocess. As shown in FIG. 3, in some embodiments a removing process mayuse a removing device 305. In some embodiments, removing device 305 maybe a stamp, a punch, or a ‘cookie cutter’ device having a cuttingelement or blade configured with a hollow construction that defines adesired internal configuration 306. In some embodiments, a removingprocess may include pressing down removing device 305, e.g., in adirection of arrow 307, to stamp or punch through flex modifier material301 to form a multi-layer flex modifier component 400, each layer offlex modifier component 400 having a configuration 306 corresponding toconfiguration 306 of hollow removing device 305, as shown by dashedlines 306 in each of first layer 302, second layer 303, and third layer304 in FIG. 3. It will be appreciated that a configuration of removingdevice 305, including internal shape 306, may be selected to achieve adesired configuration of a resulting flex modifier component 400 (e.g.,corresponding to flex modifier component 208 in FIG. 2) based on thepresent disclosure.

FIG. 4 is a plan view of an embodiment of a multi-layer flex modifiercomponent 400. In some embodiments, flex modifier component 400 maycorrespond to flex modifier component 208 in FIG. 2. In someembodiments, flex modifier component 400 may have a multi-layerconstruction corresponding to multi-layer flex modifier material 301 andhave a configuration (including at least shape 306), as shown in FIG. 3.In some embodiments, flex modifier component 400 may be made by aremoving process (e.g., a stamping or punching process) as illustratedin FIG. 3 and may have a configuration (including at least shape 306)corresponding to an interior configuration 306 of removing device 305 ofFIG. 3.

FIG. 5 is a cross-sectional view of an embodiment of flex modifiercomponent 400 of FIG. 4, taken along section line 5-5 of FIG. 4. In someembodiments, first layer 302 may include a binder or bonding material.In some embodiments first layer 302 may be an extruded hot melt filmlayer, such as an extruded thermoplastic hot melt film.

A construction of second layer 303 and optional third layer 304 may varyin different embodiments. In some embodiments, second layer 303 and/oroptional third layer 304 may be a fiber fabric material, such as anon-woven fiber mat or other non-woven fiber fabric material. As shownin FIG. 5, in some embodiments second layer 303 and/or third layer 304may include a fusion bonded non-woven fiber mat or fiber fabricmaterial. For example, as shown in FIG. 5, in some embodiments secondlayer 303 and/or third layer 304 may include a non-woven fiber fabricmaterial that is infused or impregnated with mold material or otherbonding material, illustrated in FIG. 5 as bold dots 514. In someembodiments, at least a portion of infused mold material or bondingmaterial 514 may be the same as, or mold compatible or bond compatiblewith, a material of first layer 302. It will be appreciated thatinfusing second layer 303 and/or third layer 304 with a mold material orbonding material 514 that is mold compatible with a material of firstlayer 302 may strengthen flex modifier material 301 of flex modifiercomponent 400. In some embodiments, at least a portion of infused moldmaterial or bonding material 514 may be the same as, or mold compatibleor bond compatible with, a material of outer sole component 106. It willbe appreciated that infusing second layer 303 and/or third layer 304with a mold material or bonding material 514 that is mold compatible orbond compatible with a mold material of outer sole component 106 mayenable co-molding of flex modifier component 400 (e.g., flex modifiercomponent 208) with an outer sole component (e.g., outer sole component106 of FIG. 2) including at least one of a chemical bond and a physicalor mechanical bond.

A configuration of flex modifier component 400, including at leastshape, size, and thickness, may vary in different embodiments.Generally, flex modifier component 400 may have any configuration,including at least shape, size, and thickness, suitable for co-moldingwith an outer sole component at a location within a desired area of anouter sole component.

Flex modifier component 400 may have any regular or non-regulargeometric shape suitable for providing desired rigidity or flexcharacteristics at a selected location of an outer sole component. Forexample, a shape of flex modifier component 400, or an element orportion of flex modifier component 400, may include rectangular,trapezoidal, triangular, circular, elliptical, parabolic, oblong, andother shapes. In some embodiments, flex modifier component 400 may havea shape that is elongated in a longitudinal direction. For example, asshown in FIG. 4, in some embodiments flex modifier component 400 mayhave a generally rectangular shaped body 402, e.g., having a lengthL_(B) 406 and a width W_(B) 408. In some embodiments, length L_(B) 406may be greater than width W_(B) 408. In some embodiments, flex modifiercomponent 400 may have a different regular or non-regular shapegenerally having length L_(B) and width W_(B). Flex modifier component400 may have one or more extended portions. For example, as shown inFIG. 4, in some embodiments flex modifier component 400 may have agenerally rectangular extended portion 404, e.g., having a length L_(XP)410 and a width W_(XP) 412. In some embodiments, length L_(XP) 410 maybe greater than width W_(XP) 412. In some embodiments, length L_(XP) 410may be less than width W_(XP) 412. In some embodiments, extended portion404 may have a different regular or non-regular geometric shapegenerally having a longitudinal length L_(XP) and a width W.

A thickness of flexible modifier component 400 may vary in differentembodiments. Flex modifier component 400 may have any thickness selectedfor providing desired rigidity or flex characteristics to outer solecomponent 106 and sole structure 103. As shown in FIG. 5, first layer302 may have a thickness 506, second layer 303 may have a thickness 508,optional third layer 304 may have a thickness 510, and flex modifiercomponent 400 may have a thickness 512, between a first surface (i.e.,bottom surface) 502 and a second surface (i.e., top surface) 504, equalto a combined thickness of first layer 302, second layer 303, andoptional fourth layer 304. A thickness of each of first layer 302,second layer 303, and optional third layer 304 may vary depending on anumber of factors including, but not limited to, a material of eachlayer and desired rigidity or flex characteristics of flex modifiercomponent 400, outer sole component 106, and sole structure 103. Thoseskilled in the art will be able to select a construction andconfiguration of flex modifier component 400, including at leastmaterials, shape, size, and thickness, suitable for providing desiredrigidity or flex characteristics and other performance characteristicsof flex modifier component 400, outer sole component 106, and solestructure 103 of article of footwear 100, based on the presentdisclosure.

Molding System Features

FIGS. 6 to 8 illustrate embodiments of a molding system for co-moldingan outer sole component with a flex modifier component for a solestructure of an article of footwear. FIG. 6 is a perspective view of anembodiment of a molding system 600 for co-molding an outer solecomponent with a flex modifier component, with molding system 600 in anopen, pre-molding state. FIG. 7 is a perspective view of molding system600 of FIG. 6 in a closed, molding state. And FIG. 8 is a perspectiveview of molding system 600 of FIG. 6 in an open, post molding state.

A configuration of molding system 600 for co-molding an outer solecomponent with flex modifier component may vary in differentembodiments. As shown in FIG. 6, in some embodiments molding system 600generally may include a first or lower mold portion 602 having a lowermold surface 603 and a second or upper mold portion 604 having an uppermold surface 605.

A configuration of lower mold portion 602 may vary in differentembodiments. As shown in FIG. 6, in some embodiments lower mold portion602 may include at least one mold cavity formed in lower mold surface603 for molding an outer sole component. For example, in someembodiments lower mold portion 602 may include a first mold cavity 606and a second mold cavity 607 formed in lower mold surface 603. In someembodiments, a configuration of first mold cavity 606 and aconfiguration of second mold cavity 607 may be the same. In someembodiments, a configuration of first mold cavity 606 and aconfiguration of second mold cavity 607 may be different. For example,in some embodiments first mold cavity 606 and second mold cavity 607 maybe configured for molding mirror image outer sole components formatching left and right articles of footwear, e.g., for a pair of samesized articles of footwear. Accordingly, for simplicity of description,features of first mold cavity 606 will be discussed in detail, and itwill be appreciated that features of second mold cavity 607 may be thesame or substantially similar.

A configuration of mold cavity 606 may vary in different embodiments.Mold cavity 606 generally may include one or more mold surface featuresfor molding corresponding features of an outer sole component for anarticle of footwear. These molded features may include, but are notlimited to, ground surface traction element features and flex structureor flex zone features located on an exposed lower surface or peripheraledge surface of an outer sole component for an article of footwear.

Mold cavity 606 may include at least one mold surface recess for forminga traction element on an exposed surface of an outer sole component. Insome embodiments, mold cavity 606 may include a plurality of moldsurface recesses for forming a plurality of traction elements.Configurations for each of a plurality of mold surface recesses forforming a plurality of traction elements may be the same or different,variously may be grouped together, and/or variously may be arranged orconfigured to form at least one pattern of traction elements on anexposed surface of an outer sole component. In some embodiments, moldcavity 606 may include a plurality of mold surface recesses that areconfigured for forming a corresponding first plurality of tractionelements in a heel region of an outer sole component (e.g., in heelregion 110 of outer sole component 106). For example, as shown in FIG.6, in some embodiments mold cavity 606 may include a first plurality ofmold surface recesses (e.g., including mold surface recess 651, moldsurface recess 652, mold surface recess 653, and mold surface recess654) configured for forming respective traction elements on an exposedsurface of an outer sole component (e.g., for forming four generallystraight or planar blade shaped cleats arranged in a generallyrectangular pattern in heel region 110 of outer sole component 106). Insome embodiments, mold cavity 606 may include a second plurality of moldsurface recesses that are configured for forming a corresponding secondplurality of traction elements in a midfoot region and/or forefootregion of an outer sole component (e.g., in midfoot region 112 and/orforefoot region 114 of outer sole component 106). For example, as shownin FIG. 6, in some embodiments mold cavity 606 may include a secondplurality of mold surface recesses (e.g., including mold surface recess661, mold surface recess 662, mold surface recess 663, and mold surfacerecess 664) configured for forming respective traction elements on anexposed surface of an outer sole component (e.g., for forming fourconical-shaped cleats arranged in a generally rectangular or trapezoidalpattern in midfoot region 112 and/or forefoot region 114 of outer solecomponent 106). In some embodiments, mold cavity 606 may include a thirdplurality of mold surface recesses that are configured for forming acorresponding third plurality of traction elements in a forefoot regionand/or toe region of an outer sole component (e.g., in forefoot region114 and/or toe region 116 of outer sole component 106). For example, asshown in FIG. 6, in some embodiments mold cavity 606 may include a thirdplurality of mold surface recesses (e.g., including mold surface recess671, mold surface recess 672, mold surface recess 673, and mold surfacerecess 674) configured for forming a respective third plurality oftraction elements on an exposed surface of an outer sole component(e.g., for forming four conical-shaped cleats arranged in a generallyrectangular or trapezoidal pattern in forefoot region 114 and/or toeregion 116 of outer sole component 106). A number and pattern of moldsurface recesses for forming traction elements or cleats may vary basedon desired traction and performance characteristics of the outer solecomponent and article of footwear. Those skilled in the art will be ableto select a desired number and/or pattern of mold surface recesses forforming traction elements or cleats suitable for desired traction andperformance characteristics.

In some embodiments, mold cavity 606 may include a mold surface featureconfigured for forming a flex structure or flex zone of an outer solecomponent. For example, as shown in FIG. 6, in some embodiments moldcavity 606 may include a raised mold surface feature 614 located inforefoot region 114 of mold cavity 606, where raised mold surfacefeature 614 is configured to form a molded outer sole component having areduced thickness profile for a flex structure or flex zone. In someembodiments, raised mold surface feature 614 may be configured toprovide a molded outer sole component having a flex structure or flexzone with a continuous thickness profile, e.g., having a smooth taperedthickness profile. In some embodiments raised mold surface feature 614may be configured to provide a molded outer sole component having a flexstructure or flex zone with a discontinuous thickness profile, e.g.,having a stepped thickness profile. In some embodiments, raised moldsurface feature 614 may extend at least substantially across amedial-lateral width of mold cavity 606. In some embodiments, raisedmold surface feature 614 may extend across only a portion of amedial-lateral width of mold cavity 606. In some embodiments, raisedmold surface feature 614 may be located between adjacent pairs of thesecond plurality of mold surface recesses and the third plurality ofmold surface recesses (i.e., between the pair of mold surface recess 661and mold surface recess 664, and the pair of mold surface recess 672 andmold surface recess 673). In some embodiments, a location of raised moldsurfaced feature 614 generally may correspond to a location ofmetatarsals adjacent the ball of the foot when disposed within anarticle of footwear.

In some embodiments, mold cavity 606 may include at least one moldsurface feature located in forefoot region 114 of mold cavity 606, wherethe at least one mold surface feature is configured to form a moldedouter sole component having a reduced width profile for a flex structureor flex zone. As shown in FIG. 6, in some embodiments, mold cavity 606may include at least one of a notched mold surface portion 681 locatedat medial side 118 and a notched mold surface portion 682 located atlateral side 120 of mold cavity 606. In some embodiments, notched moldsurface portion 681 and notched mold surface portion 682 may be locatedbetween adjacent pairs of the second plurality of mold surface recessesand the third plurality of mold surface recesses (i.e., between the pairof mold surface recess 661 and mold surface recess 664, and the pair ofmold surface recess 672 and mold surface recess 673). In someembodiments, the locations of notched mold surface portion 681 andnotched mold surface portion 682 generally may correspond to a locationof metatarsals adjacent the ball of the foot when disposed within anarticle of footwear. In some embodiments, notched mold surface portion681 and notched mold surface portion 682 may be located to correspondwith raised mold surface feature 614.

A configuration of upper mold portion 604 may vary in differentembodiments. Upper mold portion 604 generally may include mold featuresthat complement mold features of lower mold portion 602 to form a moldedouter sole component.

Upper mold portion 604 includes at least one mold surface portion formolding an outer sole component. For example, as shown in FIG. 6, insome embodiments upper mold portion 604 may include a first mold surfaceportion 616 that complements first mold cavity 606 of lower mold portion602 and a second mold surface portion 617 that complements second moldcavity 607 of lower mold portion 602. In some embodiments, aconfiguration, including at least plan shape, of first mold surfaceportion 616 may be the same or substantially similar to a configurationof first mold cavity 606, and a configuration, including at least planshape, of second mold surface portion 617 may be the same orsubstantially similar to a configuration of first mold cavity 607. Insome embodiments, a configuration of first mold surface portion 616 anda configuration of second mold surface portion 617 may be the same. Insome embodiments, a configuration of first mold surface portion 616 anda configuration of second mold surface portion 617 may be different. Forexample, in some embodiments first mold surface portion 616 and secondmold surface portion 617 may be configured for molding mirror imageouter sole components for matching left and right articles of footwear,e.g., a pair of same sized articles of footwear. Accordingly, forpurposes of simplicity, features of first mold surface portion 616 willbe discussed in detail, and it will be appreciated that features ofsecond mold surface portion 617 may be the same or substantiallysimilar.

Mold surface portion 616 may include one or more mold surface featuresfor forming various features corresponding to features of mold cavity606 for forming an outer sole component of an article of footwear. Thesemolded features may include, but are not limited to, surface contourfeatures of an upper surface of an outer sole component, e.g., to belocated next to a foot disposed in an interior of the article offootwear, and flex structure or flex zone features located on an exposedperipheral edge surface of the outer sole component. For example, insome embodiments at least a portion of a perimeter edge of mold surfaceportion 616 may include a curved surface contour configured to form alip, e.g., for following a lower perimeter portion of an upper (e.g.,upper 102 of assembled article of footwear 100 in FIGS. 1 and 2). Asshown in FIG. 6, in some embodiments mold surface portion 616 mayinclude a notched mold surface portion 683 located at medial side 118and a notched mold surface portion 684 (see also FIG. 8) located atlateral side 120 of mold surface portion 616. In some embodiments, alocation of notched surface portion 683 and notched surface portion 684of mold surface portion 616 may correspond with notched surface portion681 and notched surface portion 682 of mold cavity 606.

FIGS. 6 to 8 illustrate exemplary processes for molding an outer solecomponent with a co-molded flex modifier component for a sole structureof an article of footwear using a molding system of FIG. 6. In someembodiments, these processes may be used for molding outer solecomponent 106 with co-molded flex modifier component 208 of FIG. 2.

As shown in FIGS. 6 to 8, processes for molding an outer sole componentwith co-molded flex modifier component may include disposing an outersole component blank and a flex modifier component in a mold cavity ofthe molding system and closing the molding system under pressure and/orheat to co-mold the outer sole component blank and flex modifiercomponent to form an outer sole component with a co-molded flex modifiercomponent. For example, as shown in FIG. 6, in some embodiments a firstouter sole component blank 620 and a second outer sole component blank621 respectively may be disposed in first mold cavity 606 and secondmold cavity 607 of lower mold portion 602, a first flex modifiercomponent 622 and a second flex modifier component 623 respectively maybe disposed at selected locations on upper surfaces of first outer solecomponent blank 620 and second outer sole component blank 621, and uppermold portion 604 may be closed, e.g., in a direction of arrows 630. Insome embodiments, a configuration, including at least size and shape, offirst outer sole component blank 620 and second outer sole componentblank 621 may be selected to generally correspond to a configuration ofrespective mold cavity 606 and mold cavity 607 of lower mold portion 602and corresponding mold surface portion 616 and mold surface portion 617of upper mold portion 604. In some embodiments, a volume of moldmaterial of each of outer sole component blank 620 and outer solecomponent blank 621 may be selected to generally correspond to a volumeof respective mold cavity 606 and mold cavity 607 of lower mold portion602 and corresponding mold surface portion 616 and mold surface portion617 of upper mold portion 604. It will be appreciated that, in thismanner, a process of molding an outer sole component with co-molded flexmodifier component using molding system 600 may enable the mold materialto flow and fully fill all mold features of mold cavity 606 and moldcavity 607 and minimize an amount of loss of mold material.

FIG. 7 illustrates molding system 600 in a closed, molding state. Forexample, as shown in FIG. 7, upper mold component 604 may be closed in adirection of arrows 702 to engage lower mold component 602 and closemolding system 600. In some embodiments, at least one of heat and/orpressure (e.g., in a direction of closing the molding system) may beapplied to at least one of lower mold portion 602 and/or upper moldportion 604, at a temperature and/or at a pressure and for a timesufficient to co-mold a mold material of outer sole component blank 620and a mold material of flex modifier component 622. After co-moldingouter sole component blank 620 and flex modifier component 622 inmolding system 600 for a desired molding time, application of pressuremay be released and/or application of heat may be removed.

FIG. 8 illustrates molding system 600 in an open, post molding state. Asshown in FIG. 8, after a molding process using mold system 600 uppermold portion 604 may be removed from lower mold portion 602, e.g., byopening upper mold portion 602 in a direction of arrows 802. As shown inFIG. 8, in some embodiments a first unfinished molded outer solecomponent 804 and a second unfinished molded outer sole component 805may have excess or residual mold material located at one or moreperimeter portion(s) of mold cavity 606 and/or mold cavity 607 of lowermold portion 602. For simplicity of description, this disclosure willdescribe these features with respect to first unfinished molded outersole component 804. For example, as shown in FIG. 8, in some embodimentsexcess or residual mold material may form one or more fin(s) of moldmaterial between lower mold portion 602 and upper mold portion 604 atone or more peripheral portion(s) of mold cavity 606. In someembodiments, mold cavity 606 may be provided with a reserve moldmaterial recess (not shown) that is in fluid communication with moldcavity 606, e.g., at a peripheral edge of a mold surface of mold cavity606, into which excess or residual mold material in mold cavity 606 mayflow during a molding process. In this case, in some embodiments aresulting unfinished molded outer sole component 804 may include aresidual molded feature (such as a fin 903, shown in FIG. 9, describedbelow) formed by excess or residual mold material on an exposed surfaceof molded outer sole component 804. Those skilled in the art willappreciate molding materials and molding processes suitable forcontrolling an amount of mold material used and resulting residual orexcess mold material.

FIG. 9 illustrates in top plan view an embodiment of an unfinishedmolded outer sole component 900 including an outer sole component body902 with a co-molded flex modifier component 904, removed from a moldsystem but prior to a finishing process. In some embodiments, unfinishedmolded outer sole component 900 may correspond to molded outer solecomponent 804 or molded sole component 805 of FIG. 8. As shown in FIG.9, in some embodiments unfinished molded outer sole component 900 mayinclude outer sole component body 902 having one or more fin(s) 903 ofmold material extending from a peripheral edge, e.g., a medial and/orlateral side edge, of body 902. One or more fin(s) 903 or other moldedfeature of excess or residual mold material may be removed from body 902in a removing process, such as a cutting process, using a removal device906, such as a knife blade, a heat blade, a laser cutter, or anothercutting device. Those skilled in the art will be able to select afinishing process suitable for providing desired finished appearance andperformance characteristics based on the present disclosure.

FIGS. 10 to 12 illustrate embodiments of an outer sole component with aco-molded flex modifier component. FIG. 10 illustrates in top plan viewembodiments of an outer sole component 1000. FIG. 11 is across-sectional view of outer sole component 1000 of FIG. 10, takenalong section line 11-11 of FIG. 10. And FIG. 12 is a side perspectiveview of outer sole component 1000 of FIGS. 10 and 11 in a flexedconfiguration. In some embodiments, outer sole component 1000 maycorrespond to molded outer sole component 900 of FIG. 9 following afinishing process (i.e., post finishing process). Accordingly, forsimplicity of description, elements of outer sole component 1000 may beindicated with corresponding reference numbers from unfinished moldedouter sole component 900 of FIG. 9. In some embodiments, outer solecomponent 1000 may result directly from a molding process of moldingsystem 600 of FIGS. 6 to 8, without requiring any finishing process. Forexample, in some embodiments a volume of mold material in a moldingprocess of FIGS. 6 to 8 may be selected so that no excess or residualmold material results from the molding process. In some embodiments,outer sole component 1000 may correspond to outer sole component 106 ofouter sole structure 103 of FIG. 2. Accordingly, elements of outer solecomponent 1000 may be indicated with corresponding reference numbersfrom outer sole component 106 of FIG. 2 to describe certain features ofouter sole component 1000.

As shown in FIG. 10, in some embodiments body 902 of outer solecomponent 1000 may be co-molded with flex modifier component 904. Insome embodiments, flex modifier component 904 may correspond to flexmodifier component 208 of FIG. 2. In some embodiments, flex modifiercomponent 904 may correspond to flex modifier component 400 of FIGS. 4and 5. In some embodiments, flex modifier component 904 may correspondto flex modifier component 622 or flex modifier component 623 in amolding process of FIGS. 6 to 8.

A construction of body 902 may vary in different embodiments. Body 902of outer sole component 1000 generally may be formed of any materialsuitable for contact with a ground surface. In some embodiments, outersole component 1000 may be formed of an abrasion resistant material. Insome embodiments, outer sole component 1000 may be formed of a moldmaterial, such as a rubber mold material, by a molding process using amolding system and molding process of FIGS. 6 to 8.

Outer sole component 1000 may include at least one traction element onan exposed or bottom surface of outer sole component 1000. As shown inFIGS. 10 to 12, in some embodiments outer sole component 1000 mayinclude one or more traction elements in one or more regions of outersole component 1000, e.g., in one or more of heel region 110, midfootregion 112, forefoot region 114, and/or toe region 116 of outer solecomponent 1000. As shown in FIGS. 10 to 12, in some embodiments outersole component 1000 may include a first plurality of traction elementsin heel region 110. As shown in FIG. 10, in some embodiments outer solecomponent 1000 may include four traction elements (e.g. traction element951, traction element 952, traction element 953, and traction element954) arranged in a pattern around a central portion 908 of heel region110. As shown in FIGS. 10 to 12, in some embodiments the first pluralityof traction elements may be blade cleats arranged in a generallyrectangular or trapezoidal pattern. In some embodiments, outer solecomponent 1000 may include a second plurality of traction elements,e.g., in midfoot region 112 and/or forefoot region 114. As shown in FIG.10, in some embodiments outer sole component 1000 may include fourtraction elements (e.g., traction element 961, traction element 962,traction element 963, and traction element 964) arranged in a pattern inmidfoot region 112 and/or forefoot region 114. As shown in FIGS. 10 to12, in some embodiments the second plurality of traction elements may beconical-shaped cleats arranged in a generally rectangular or trapezoidalpattern. In some embodiments, outer sole component 1000 may include athird plurality of traction elements in forefoot region 114 and/or toeregion 116. As shown in FIG. 10, in some embodiments outer solecomponent 1000 may include four traction elements (e.g., tractionelement 971, traction element 972, traction element 973, and tractionelement 974) arranged in a pattern in forefoot region 114 and/or toeregion 116. As shown in FIGS. 10 to 12, in some embodiments the thirdplurality of traction elements may be conical-shaped cleats arranged ina generally rectangular or trapezoidal pattern. In some embodiments, oneor more of these traction elements may be integrally molded as a singlepiece with outer sole component 1000, e.g., in a molding system andprocess of FIGS. 6 to 8. It will be appreciated that such molding systemand process thus may provide significant advantages in cost andmanufacturing. Those skilled in the art will appreciate alternativetraction element structures, patterns, and methods of manufacturesuitable for a desired article of footwear and desired performancecharacteristics.

A thickness profile of outer sole component 1000 may vary in differentembodiments. Outer sole component 1000 may include a thickness profilethat provides desired rigidity characteristics and/or facilitatesbending or flex characteristics of outer sole component 1000. As shownin FIG. 11, in some embodiments outer sole component 1000 generally mayhave a thickness profile including a thickness 1102 at flex modifiercomponent 904 and portions of outer sole component 1000 locatedproximate to flex modifier component 904, a thickness 1104 in forefootregion 114, a thickness 1106 in a flex structure or flex zone 912, athickness 1108 in toe region 116, and a thickness 1110 in heel region110. As discussed below, controlling a thickness profile of outer solecomponent 1000 may facilitate controlling rigidity, bending, flex, andother performance characteristics of outer sole component 1000.

A thickness profile of outer sole component 1000 in midfoot region 112may vary in different embodiments. Outer sole component 1000 may have athickness profile including a thickness 1102 in midfoot region 112sufficiently thick to enable flex modifier component 904 to besubstantially embedded in, and co-molded with, outer sole component body902. For example, in some embodiments thickness 1102 may beapproximately 2 to 3 mm greater than a thickness of adjacent portions ofouter sole component 1000, e.g., thickness 1104 at forefoot region 114and/or thickness 1110 at heel portion 110. It will be appreciated thatthis configuration may enable outer sole component 1000 and flexmodifier component 904 to be at least substantially embedded in body 902of outer sole component 1000 and/or co-molded with body 902 of outersole component 1000 including at least one of a chemical bond and amechanical bond.

In some embodiments, outer sole component 1000 may have a thicknessprofile including a reduced thickness on medial side 118 and/or lateralside 120 at midfoot region 112 of outer sole component 904. In someembodiments, outer sole component 1000 may have a thickness profile thattapers in a medial and/or lateral direction from flex modifier component904. It will be appreciated that such a tapered configuration mayprovide or facilitate a desired torsional rigidity characteristic ofouter sole component 1000 at midfoot region 112. It also will beappreciated that controlling a configuration (including at leastthickness, width, and shape) of flex modifier component 904 mayfacilitate controlling a torsional rigidity characteristic of outer solecomponent 1000 about midfoot region 112. It further will be appreciatedthat controlling a thickness profile of midfoot region 112, includingthickness 1102 and a thickness of portions of body 902 medial andlateral of flex modifier component 904, may enable or facilitateproviding desired rigidity, flex, and performance characteristics ofouter sole component 1000 at midfoot region 112.

A thickness profile of outer sole component 1000 may cooperate with aconfiguration, location, and orientation of co-molded flex modifiercomponent 904 to provide desired flex modification characteristics ofouter sole component 1000. In some embodiments, a configuration(including at least size and shape), location, and/or orientation offlex modifier component 904 may be selected to cooperate with otherfeatures of outer sole component 1000 to provide desired rigidity, flex,and/or other performance characteristics. For example, as shown in FIGS.10 to 12, in some embodiments a configuration, location, and orientationof flex modifier component 904 may cooperate with a location of at leastthe third plurality of traction elements located in heel region 110. Insome embodiments, flex modifier component 904 may have an elongated body904 and an extended portion 905 that have a configuration, location, andorientation that cooperate with a configuration (including at leastnumber and/or pattern) of the third plurality of traction elements inheel region 110. In some embodiments, a location and orientation of flexmodifier component 904 may be selected relative to other features ofouter sole component 1000 to facilitate a desired relative locationand/or orientation of flex modifier component 904. As shown in FIG. 10,in some embodiments flex modifier component 904 may have a generallyrectangular body 904 with a generally rectangular extended portion 905,where body 904 generally is located in midfoot region 112 and orientedat an angle relative to a longitudinal or lateral direction of outersole component 1000 (e.g., in some embodiments flex modifier component904 may be oriented at an angle a relative to generally longitudinalsection line 11-11). In this configuration, extended portion 905 mayextend into central region 908 of heel region 110 between the thirdplurality of traction elements (e.g., between traction element 951,traction element 952, traction element 953, and traction element 954).It will be appreciated that this configuration, location, andorientation of flex modifier component 904 may provide a desired firstrigidity or flex characteristic and first torsional rigiditycharacteristic in midfoot region 112, a desired second rigidity or flexcharacteristic in at least a portion of central region 908 of heelregion 110, and a desired third rigidity or flex characteristic in anarea of heel region 110 including the third plurality of tractionelements but excluding at least a portion of central region 908 thatincludes extended portion 905 of flex modifier component 904. Thoseskilled in the art will be able to select a desired configuration,location, and/or orientation of flex modifier component 904, includingany extended portion (e.g., extended portion 905), and a desiredconfiguration of traction elements or other features of outer solecomponent 1000, suitable for achieving desired rigidity, flex, and otherperformance characteristics of outer sole component 1000 and a solestructure and article of footwear incorporating outer sole component1000.

A thickness profile of outer sole component 1000 in heel region 110 mayvary in different embodiments. In some embodiments, outer sole component1000 may have a thickness profile including a reduced thickness profilein heel region 110, e.g., where a thickness 1110 is less than athickness 1102. In some embodiments, outer sole component 1000 mayinclude a tapered thickness profile in at least a portion of a directionfrom midfoot region 112 to heel region 110. In some embodiments, asshown in FIGS. 11 and 12, outer sole component 1000 may include athickness profile that forms a cupped configuration in heel region 110that is configured to receive and securely support a heel of a foot withcomfort. It will be appreciated that such a configuration, including areduced thickness or tapered thickness profile, also may provide desiredrigidity, flex, and/or performance characteristics in heel region 110.

A thickness profile of outer sole component 1000 in forefoot region 114and toe region 116 may vary in different embodiments. In someembodiments outer sole component 1000 may include a thickness profilethat forms a flex structure or flex zone that facilitates localizedbending and flexing of outer sole component 1000 in forefoot region 114and/or toe region 116. For example, as shown in FIGS. 10 to 12, in someembodiments outer sole component 1000 may include a flex structure orflex zone 912 in forefoot region 114. In some embodiments, flexstructure or flex zone 912 may be located in forefoot region 114 betweenthe second plurality of traction elements generally located in midfootregion 112 and/or forefoot region 114 and the third plurality oftraction elements located in forefoot region 114 and/or toe region 116.In some embodiments, flex structure or flex zone 912 may be locatedbelow metatarsals proximate the ball of the foot, where a foot islocated in an article footwear including outer sole component 1000. Insome embodiments, outer sole component 1000 may include a thicknessprofile that facilitates bending or flexing characteristics at flexstructure or flex zone 912 of outer sole component 1000. For example, asshown in FIGS. 10 to 12, in some embodiments outer sole component 1000may include a thickness profile that tapers down from thickness 1104 inforefoot region 114 to thickness 1106 at flex structure or flex zone 912and tapers back up to thickness 1108 at toe region 116. That is, in someembodiments thickness 1106 may be less than at least one of thickness1104 and thickness 1108. In some embodiments, thickness 1104 may begreater than thickness 1108. And in some embodiments, outer solecomponent 1000 generally may taper in a direction from flex modifiercomponent 904 to toe region 116. Those skilled in the art will be ableto select a thickness profile suitable for providing a desired flexingand/or bending characteristic in forefoot region 114 (and toe region116), including at flex structure or flex zone 912.

A width profile of outer sole component 1000 at flex structure or flexzone 912 may vary in different embodiments. In some embodiments, outersole component 1000 may include a notched or cut-out portion located ona medial side and/or a lateral side in forefoot region 114 thatfacilitates localized bending or flexing of outer sole component 1000,e.g., at flex structure or flex zone 912 in forefoot region 114. Forexample, as shown in FIG. 10, in some embodiments a first notched orcut-out portion 914 and/or a second notched or cut-out portion 916 maybe provided on opposing medial side 118 and lateral side 120 of outersole component 1000. In some embodiments, notched or cut-out portion 914and/or notched or cut-out portion 916 may form flex structure or flexzone 912 of outer sole component 1000. In some embodiments, notched orcut-out portion 914 and/or notched or cut-out portion 916 may correspondand cooperate with a tapered thickness profile of flex structure or flexzone 912. In some embodiments, outer sole component 1000 may include awidth profile that tapers down from a width 1002 at forefoot region 114to a width 1004 in flex structure or flex zone 912 back up to a width1006 adjacent toe region 116. It will be appreciated that such a taperedwidth configuration may facilitate localized bending and flexing at flexstructure or flex zone 912 of outer sole component 1000. Those skilledin the art will appreciate alternative notched or cut-out configurationssuitable for providing desired flexing, bending, or other performancecharacteristics of outer sole component 1000.

It will be appreciated that each of the above embodiments, including athickness profile and/or width profile at flex structure or flex zone912, may provide desired rigidity and flex characteristics at flexstructure or flex zone 912. It further will be appreciated that each ofthese embodiments may facilitate a smooth response characteristic (e.g.,bending without buckling of the sole structure) and other desiredperformance characteristics for a sole structure and article offootwear, e.g., when outer sole component 1000 of the sole structure andarticle of footwear is bent or flexed at flex structure or flex zone 912in a direction of arrow 1210 of FIG. 12.

Manufacturing Process Features

FIG. 13 is a flow diagram illustrating processes for making a flexmodifier component. As shown in FIG. 13, in some embodiments a methodfor making a flex modifier component generally may include processes ofpreparing a flex modifier material 1301 and forming a flex modifiercomponent from the flex modifier material 1302.

Process 1301 may vary in different embodiments. In some embodiments,process 1301 may include preparing a sheet of flex modifier material.For example, in some embodiments process 1301 may include preparing amulti-layer sheet of flex modifier material, as illustrated in FIG. 3.In some embodiments, process 1301 may include preparing a multi-layersheet of flex modifier material including at least one fiber materiallayer and at least one binder or bonding material layer. In someembodiments, process 1301 may include preparing a multi-layer sheet offlex modifier material, e.g., having an extruded hot melt filmsandwiched between fiber fabric material layers, as illustrated in FIGS.3 to 5.

Process 1302 may vary in different embodiments. In some embodiments,process 1302 may include removing a flex modifier component from a sheetof flex modifier material. In some embodiments, process 1302 may includeremoving a flex modifier component from a sheet of flex modifiermaterial using a removing device, such as a cutting device, a stampdevice, or a cookie cutter device, as illustrated in FIG. 3.

FIG. 14 is a flow diagram illustrating processes for making a solestructure for an article of footwear including an outer sole componentwith a co-molded flex modifier component. As shown in FIG. 14, in someembodiments a method for making a sole structure for an article offootwear may include placing an outer sole component blank and a flexmodifier component in a molding system (process 1401), and co-moldingthe outer sole component blank and the flex modifier component to forman outer sole component with a co-molded flex modifier component in themolding system (process 1402). In some embodiments, a method for makinga sole structure for an article of footwear optionally may includefinishing a molded outer sole component with a co-molded flex modifiercomponent (process 1403), and/or associating one or more othercomponents with the molded outer sole component with a co-molded flexmodifier component (process 1404). Optional processes 1403 and 1404 areillustrated in FIG. 14 using dashed lines.

Process 1401 may vary in different embodiments. In some embodiments,process 1401 may include disposing an outer sole component blank in afirst (e.g., lower) mold portion of a molding system that is configuredto mold an outer sole component having a desired configuration,including at least size and shape, disposing a flex modifier componentat a desired location (at least longitudinal and/or lateral location andorientation) on an exposed top or upper surface of the outer solecomponent blank, closing a second (e.g., upper) mold portion of themolding system with the first mold portion of the molding system, andco-molding the outer sole component blank with the flex modifiercomponent in the molding system, e.g., using a hot press moldingprocess. In some embodiments, disposing a flex modifier component on anexposed upper surface of an outer sole component blank may includelocating the flex modifier component, or a portion of the flex modifiercomponent (e.g., an extended portion of the flex modifier component),relative to one or more mold features of a mold cavity of the moldingsystem. For example, in some embodiments disposing a flex modifiercomponent on an exposed upper surface of the outer sole component blankmay include locating an extended portion of the flex modifier relativeto one or more recess features of the mold cavity that correspond to oneor more traction element(s) of a molded outer sole component formed bythe molding system. In some embodiments, disposing the flex modifiercomponent on an exposed upper surface of the outer sole component blankmay include orienting the flex modifier component relative to the outersole component blank or mold cavity of the molding system. For example,in some embodiments disposing the flex modifier component on the exposedupper surface of the outer sole component blank may include disposingthe flex modifier component at a desired angle a relative to alongitudinal and/or lateral direction of a molded outer sole componentformed by the molding system.

In some embodiments, process 1402 may include co-molding a mold materialof the flex modifier component with a mold material of the outer solecomponent blank. For example, in some embodiments an outer solecomponent blank may include a first mold material and a flex modifiercomponent may include a fiber material that is infused or impregnatedwith a second mold material that is the same as, or mold compatiblewith, the first mold material, and process 1402 may include co-moldingthe outer sole component blank and the flex modifier component using ahot press molding process that naturally fuses or blends the moldmaterial of the flex modifier component with the mold material of theouter sole component so that the flex modifier component is at least oneof chemically and mechanically bonded with the molded outer solecomponent formed by the molding system. In some embodiments, a hot pressmolding process may be controlled to co-mold a plastic mold material ofa flex modifier component with a rubber mold material of an outer solecomponent at a temperature and pressure and for a time sufficient toco-mold the mold materials but not overcook the rubber mold material soas to make the molded rubber material brittle. It will be appreciatedthat such hot press molding process may improve a durability of themolded rubber outer sole component, and may reduce or eliminate any needfor applying any final coating to the molded rubber or for performingany other finishing process of the molded outer sole component.

In some embodiments, optional process 1403 may include finishing aperipheral edge of the outer sole component. In some embodiments,finishing a peripheral edge may include removing a fin or web of moldmaterial from the molded outer sole component, e.g., by a cutting ortrimming process using a removing device, such as a knife blade, a hotmelt blade, a laser cutter, or another cutting device.

In some embodiments, optional process 1404 may include associating oneor more additional components with an outer sole component and co-moldedflex modifier component. For example, in some embodiments an outer solecomponent with a co-molded flex modifier component may be associatedwith an optional midsole component to form a multi-layer sole structurefor an article of footwear. In some embodiments, an outer sole componentwith a co-molded flex modifier component may be associated with one ormore removable traction elements. In some embodiments, an outer solecomponent with a co-molded flex modifier component may be directly orindirectly (e.g., via an optional midsole) associated with an upper toform an article of footwear.

Benefits explained herein with respect to different elements of, orprocesses for making, outer sole component 106, sole structure 103,outer sole component 900, and outer sole component 1000 may be providedby the elements or processes individually, and further may be increasedby combining certain of the elements or processes together.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting, and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible. Accordingly, the embodiments are not to belimited except in light of the attached claims and their equivalents.Also, various modifications and changes may be made within the scope ofthe attached claims.

What is claimed is:
 1. A sole structure for an article of footwear,comprising: an outer sole component formed of a first mold material, theouter sole component having an exposed surface configured to engage aground surface and an interior surface opposite the exposed surface; anda flex modifier component, the flex modifier component being formed of afiber material and a second mold material, the flex modifier componentbeing co-molded with the outer sole component at the interior surface ofthe outer sole component.
 2. The sole structure according to claim 1,wherein the flex modifier component has a multi-layer construction thatincludes at least a first layer of fiber material.
 3. The sole structureaccording to claim 2, wherein the at least first layer of fiber materialincludes a non-woven fiber fabric material.
 4. The sole structureaccording to claim 2, wherein the at least first layer of fiber materialincludes a fusion bonded non-woven fiber fabric material.
 5. The solestructure according to claim 2, wherein the at least first layer offiber material is impregnated with a polymer material.
 6. The solestructure according to claim 5, wherein the polymer material is moldcompatible with the first mold material of the outer sole component. 7.The sole structure according to claim 5, wherein the polymer material isa styrene-coated polymer material.
 8. The sole structure according toclaim 2, wherein the multi-layer construction includes an extruded hotmelt film.
 9. The sole structure according to claim 2, wherein themulti-layer construction includes an extruded hot melt film sandwichedbetween fiber material layers.
 10. The sole structure according to claim2, wherein the multi-layer construction includes an extrudedthermoplastic hot melt film sandwiched between fusion bonded non-wovenfiber fabric material layers impregnated with styrene-coated polymer.11. The sole structure according to claim 1, wherein the flex modifiercomponent is co-molded with the outer sole component such that thesecond mold material of the flex modifier component fuses or blends withthe first mold material of the outer sole component to create a chemicaland mechanical bond.
 12. The sole structure according to claim 1,wherein the outer sole component has a first configuration, the flexmodifier component has a second configuration, and the flex modifiercomponent is disposed at a location of the outer sole component selectedso that the second configuration of the flex modifier componentcooperates with the first configuration of the outer sole component tomodify a flex characteristic of the outer sole component substantiallyonly at the selected location of the outer sole component.
 13. The solestructure according to claim 12, wherein the second configuration of theflex modifier component includes an elongated shank that extends througha midfoot region of the sole structure generally from a heel region to aforefoot region of the sole structure.
 14. The sole structure accordingto claim 13, wherein the elongated shank is generally rectangular. 15.The sole structure according to claim 13, wherein the firstconfiguration of the outer sole component includes a plurality oftraction elements arranged in a pattern, and the elongated shank has atleast one extended portion that extends within a region located betweenthe plurality of traction elements of the first configuration of theouter sole component.
 16. The sole structure according to claim 1,wherein the outer sole component has a first configuration including aplurality of traction elements arranged in a forefoot region and a heelregion of the outer sole component, the flex modifier component has asecond configuration including an elongated shank that extends through amidfoot region of the outer sole component generally from the heelregion to the forefoot region of the outer sole component, and the flexmodifier component is disposed at a location of the outer sole componentselected so that the second configuration of the flex modifier componentcooperates with the first configuration of the outer sole component tomodify a flex characteristic of the outer sole component substantiallyonly at the selected location of the outer sole component outside of anarea that includes the plurality of traction elements.
 17. An article offootwear, comprising: an upper; and a sole structure associated with theupper, the sole structure including: an outer sole component formed of afirst mold material, the outer sole component having an exposed surfaceconfigured to engage a ground surface and an interior surface oppositethe exposed surface; and a flex modifier component, the flex modifiercomponent being formed of a fiber material and a second mold material,the flex modifier component being co-molded with the outer solecomponent at the interior surface of the outer sole component.
 18. Thearticle of footwear according to claim 17, wherein the sole structurefurther includes a midsole component disposed between the upper and theouter sole component with the co-molded flex modifier component.
 19. Amethod of making a sole structure for an article of footwear,comprising: disposing an outer sole component blank of a first moldmaterial in a mold cavity of a molding system that is configured tocorrespond with an outer sole component of the sole structure; disposinga flex modifier component that includes a fiber material and a secondmold material on an exposed upper surface of the outer sole componentblank; and co-molding the outer sole component blank and the flexmodifier component in the molding system to form the outer solecomponent, with the co-molded flex modifier component located at aninterior surface of the outer sole component.
 20. The method accordingto claim 19, further comprising; preparing a multi-layer flex modifiermaterial including an extruded thermoplastic hot melt film sandwichedbetween fusion bonded non-woven fiber fabric material impregnated with astyrene-coated polymer; and forming the flex modifier component from themulti-layer flex modifier material.